Solar panel support structure

ABSTRACT

Roof-top solar panel system that is held in place on a roof by the solar array. The system includes a softened design including rounded component edges that protect the roof from uplift damage by solar panel structure components with or without mechanical anchoring or ballast.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation In Part Application of International Application Serial No. PCT/US2011/001562, titled: SOLAR PANEL SUPPORT STRUCTURE, filed Sep. 9, 2011, claiming priority of U.S. Provisional Application No: 61/381,230, titled: SOLAR PANEL SUPPORT STRUCTURE, filed on Sep. 9, 2010, both herein incorporated by reference.

FIELD OF THE INVENTION

This invention relates to a combination roofing system and solar panel support structure for use with solar energy panels on roofs and decks, in particular the array and solar panel support structure holds the roof in place.

BACKGROUND OF THE INVENTION

Commercially available solar racks are incompatible with the existing roof-top materials. The racks and/or supporting structure must be fastened directly to the roof or ballasted around its perimeter with weights. Such racks damage or slice through the roofing materials, such as waterproof membranes, over time. Existing solar rack systems also have disadvantages when solar rack systems are shipped with integral roof protection membranes, because such systems make it difficult to position the rack on the roof and provide roof maintenance. In addition, existing membrane systems with racks have redundant fastening mechanisms and do not recognize and incorporate the benefits of the solar rack as ballast. The practice of using a ballast material such as pavers, stones, or other materials with sufficient weight to counteract wind uplift forces are well documented in the roofing industry. Typically, a minimum weight of 10 lbs. per square foot is required when round river stone is utilized. This represents the minimal condition and the ballast weights are increased in the perimeters, corners and field of the roof in accordance with industry accepted design guidelines. The ability of a ballasted roofing system to withstand wind uplift forces given the relatively low weight of the ballast versus the design uplift pressure is due to the geometry of the stone (generally round) and the wind interaction with the shape. Pavers or other square or rectangular flat plates usually require an interlocking mechanism or increased weight to perform the same function. Racking systems utilizing additional ballast weight may exceed the safe capacity of the structure. As a result solar rack systems that minimize the additional weight required are desirable to the market since the structural impact is lessened.

SUMMARY OF THE INVENTION

The present invention is a roofing membrane and integrated solar panel support structure that is compatible with any existing roofing substrate and that optimizes the attachment benefits of the solar rack by providing a combination of a solar panel support structure and a waterproofing membrane that is secured to a roof, for example, by using the solar panel support structure and roofing membrane as ballast, such that few or no other fastening system or mechanism or wind reduction or pressure equalizing devices attached thereto are needed to complete the installation of the photovoltaic (PV) assembly to the roof. The bottom of the support rails of the solar panel rack also have a rounded (softened) designed such that when the roof pillows or bounces in the wind, the roof membrane is not damaged or sliced by the rails of the solar panel structure. The softening is extended to the panel support members (run perpendicular to the support rails) and upright PV panel support brackets that attach to the support rails. The protective membrane is loosely laid on top of the existing roof and can be held in place using the weight of the present invention and solar panel support structure and solar panel array components attached thereto. The protective membrane can be used to repair a pre-existing old roof such that it is watertight. Once the new protective member is placed on the old existing roof a two-ply redundant roofing system is formed, and the aging of the old roof ceases because there is no longer any Ultraviolet light exposure to the pre-existing roof. In cases where wind uplift or seismic forces require increased resistance to lateral or uplift forces, connectors may be utilized to counteract the forces. The connectors are secured to a structural element and the solar support structure. In some cases support members of the solar rack may be used in lieu of the existing ballast to secure a loose laid roofing material (such as an Ethylene Propylene Diene Monomer (EPDM) membrane ballasted with river stone) to the structure thereby eliminating the need for pre-securing the underlying roof system. However, some embodiments may replace penetrating anchors, such as short or long spikes, with conventional ballast.

DESCRIPTION OF THE DRAWINGS

The invention is further illustrated by the following non-limiting drawings in which,

FIG. 1 is perspective view of an embodiment of the present invention in which the solar panel structure protection layer is not attached to the existing membrane/roof;

FIG. 2 is a perspective view of an embodiment of the present invention in which the solar panel structure protection layer is partially attached to the existing membrane/roof system at the edges;

FIG. 3 is a perspective view of an embodiment of the present invention in which the solar panel structure protection layer is sealed on three sides to the existing roof membrane;

FIG. 4 is a side view of an embodiment of the present invention having the solar panel structure protection layer and a support railing directly on a roof substrate, and with foot supports under one rail to illustrate one embodiment of the present invention to increase roof clearance or for additional support;

FIG. 5 is a side view of an embodiment of the present invention having the solar panel structure protection layer and a support railing directly on top of an existing roof membrane, and with foot supports under one rail to illustrate one embodiment of the present invention to increase roof clearance;

FIG. 6 a is a perspective of an embodiment of the present invention having the solar panel structure protection layer and a connector on top of an existing roof membrane;

FIG. 6 b is an illustration of a connector used to retain support rail 30 in place;

FIGS. 7A-C are side views of embodiments of the present invention having a connector attached to wood blocking which is in turn attached to the structure, wherein the post penetrates the existing roof system and new membrane requiring the installation of flashings to both membranes in order to seal the post to water penetration;

FIG. 8 is a side view of an embodiment of the present invention having a connector attached directly the base structure of the roof, wherein the post penetrates the existing roof system and new membrane requiring the installation of filler material around the post and flashings to both membranes in order to seal the post to water penetration;

FIG. 9A is a perspective view of the embodiments of the present invention shown in FIGS. 1, 2, & 3 with the solar array attached thereto;

FIG. 9B is a perspective view of the embodiments of the present invention shown in FIGS. 1, 2, & 3 without the solar array attached thereto;

FIGS. 10A and 10B are illustrations of external forces and reactive forces acting on an object, such the present invention;

FIG. 11 is side view of an embodiment of the present invention adjacent to a corner or edge roof wall;

FIG. 12 is an exploded view of an exemplary embodiment of an assembly including a support post, a corner base, and a corner clamp;

FIG. 13 is an exploded view of another exemplary embodiment of an assembly including a support post, a corner base, and a corner clamp;

FIG. 14A-14F are various pictorial views of components of an assembly;

FIG. 14G is an exploded view of assembly components with PV modules positioned for installation;

FIG. 15A is a top view of an exemplary rack system with assemblies positioned at corners of PV modules;

FIG. 15B is a side view of the rack system of FIG. 15A illustrating a plane P1 of zero degrees;

FIG. 16A is a top view of an exemplary rack system with assemblies positioned at corners of PV modules; and

FIG. 16B is a side view of the rack system of FIG. 16A illustrating a plane P2 of greater than zero degrees.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a perspective plan view of an embodiment of the present invention 1 in which the protective membrane 5 is not fixedly attached to the existing roof membrane 10 and merely overlays the existing roof membrane 10. Roof member 10 includes an upper surface 10 a. Two or more rows of support rails 30 can be positioned on top of protective membrane 5 without any adhesive or fasteners or fixturing devices used to attach or connect support rails 30 to protective membrane 5. Alternatively, support rails 30 could sit directly on the roof membrane 10 or sit on feet or risers 31.

The protective membrane 5 of the present invention 1 also protects an existing roof system from damage by solar panel structure components, such as damage during maintenance to the solar panel structure, PV panels and associated electrical system or other roof top equipment (HVAC, exhaust fans, etc), or damage incurred while relocating (horizontally or vertically) portions of an existing PV system, or damage caused by abrasion to the roof membrane 10 from “feet” or “ballast pans” that contact the roof membrane 10 and are subject to continued thermal expansion and contraction cycles. This abrasion can result in holes through the membranes 10 or a severely compromised roof system. The protective membrane 5 can be used as a new waterproofing membrane for new construction, or can be used as a new waterproofing membrane over an existing roof system. In the former case, an existing roof membrane 10 in marginal condition can be waterproofed under the solar panel structure without any preparatory repair work to the existing roof system.

Now turning to the insert in FIG. 1, support rails 30 can be generally trapezoidal shaped or any other geometric shape with rounded bottom edges 32 where the rail could contact the protective membrane 5 or roof 10. Rounded bottom edges 32 soften the contact of the surfaces to prevent cutting or tearing or excessive wear of the surfaces that results in relation motion between the surfaces due to wind induced uplift. The rounding is beneficial where the protective membrane 5 or roof 10 pillows up under a wind load and contacts the support rails 30 causing abrasion or puncture damage. The overall length 36 of support rails 30 can be shorter than length 38 of protective membrane 5. However, some embodiments of support rails 30 can have length 36 equal to or greater than length 38 of protective membrane 5. The internal cavity 39 of support rails 30 is configured to receive nuts, bolts, or other fasteners 9 to secure the solar panel supports (shown in FIG. 9B) to the system 1. Internal cavity 39 shown in the insert in FIG. 1 is an illustration of a nut/bolt insert slot to engage a head 33 of nut/bolt 9 to connect cross member 25 (FIG. 2) with support rail 30 to form the solar rack system 1 at any point along the support rail 30. The internal cavity 39 acts like a track for a variable sliding adjustment of the cross member 25 along guide rail 30.

Now turning to FIG. 9B that illustrates an embodiment 52 of the present invention including center upright members 97 and end upright members 99, discussed below, also can be slideably adjusted along guide rail 30 to any point along the length 36 (see FIG. 1) of guide rail 30. This adjustability provides flexibility in the selection of the solar array width and/or angle of incidence Ø relative to the roof upper surface by setting a distance D between cross member 25 and center upright members 97/end upright members 99. As distance D reduces, the angle of incidence Ø increases. The desired angle of incidence Ø is determined based on the position of the sun relative to the roof surface 10A, which is dependent on the time of year and latitudinal location relative to the equator. As mentioned above, an example of distance X that separates guide rails 30 ranges can from 3′ to 16′ depending upon the layout configuration. The longer distance X spans would accommodate more panels side by side supported by cross members 25 and center upright members 97 and end upright members 99. As distance X spans longer distances, then length L3 of lip 97A and L4 of lip 25A would be longer extrusions. The longer the lengths L3, L4 of lips 97A, 25A, respectively, the ratio of guide rails 30 to panels 55 (see FIG. 9A) would decrease. For example, FIG. 9A illustrates 3 guide rails 30 and 2 solar panels 55 or 3:2 ratio. As the distance X increases and lengths L3, L4 increase, then more than 2 solar panels 55 can be placed on lips 97A, 99A, 25A, such as 3 guide rails with 3 solar panels making the guide rail 30 to solar panel ratio 3:3, or 3 guide rails with 4 solar panels, 3:4 ratio, etc. However, any configuration that retains the solar rack system 52 within support rails 30 is suitable for the contemplated embodiments of the present invention.

Now turning to FIG. 2 and an insert of cross member 25 illustrating a through hole 11 to receive bolt 9 (see FIG. 1) to secure cross member 25 to support rail 30. Cross member rounded bottom edges 33 along bottom width 31 where cross member 25 could contact the protective membrane 5 or roof 10. Rounded bottom edges 33 soften the contact of the surfaces to prevent cutting or tearing or excessive wear of the surfaces that results in relation motion between the surfaces due to wind induced uplift. The rounding is beneficial where the protective membrane 5 or roof 10 pillows up under a wind load and contacts cross member 25 causing abrasion or puncture damage. Projections 27 and 29 form a recess 28 to attach the solar rack system (not shown) to the present invention.

Now returning to FIG. 1, bottom surface 95A of support rail 30 or bottom surface 95B of connector 40 (FIG. 7A) can have a surface roughness or be made of or coated with a material that has a sufficient coefficient of friction μ between adjacent surface protective membrane 5 or feet 31 (FIGS. 4 and 5) to require a horizontal force F_(x) greater than sliding friction Fμ (Fμ a equals normal force N times coefficient of friction μ) before the solar rack system 1 moves relative to the adjacent material when external force F_(external) is induced on solar rack system 1 (see FIGS. 10A and 10B). Coefficient of friction μ can be determined based on the characteristics of the mating surfaces. External force F_(external) has an X component of force F_(x) and a Y component of force F_(y). Normal force N is the resultant force of the weight of solar rack system 1 and External force Y component (F_(y)). FIG. 10A illustrates an external force F_(external) inducing a downward or negative vertical force F_(y) on the solar rack system 1. Therefore, normal force N is the addition of the downward external force F_(y) and the weight W of solar rack system 1. FIG. 10B illustrates an external force F_(external) inducing an upward or positive vertical force F_(y) on the solar rack system 1. Therefore, normal force N is the subtraction of the upward external force F_(y) from weight W of solar rack system 1. With regards to sliding friction Fμ, external force vertical force Fy could be beneficial (−Fy—see FIG. 10A)) or detrimental (+Fy—see FIG. 10B). With regards to externally induced moment M, external vertical force Fy could be beneficial (−Fy—see FIG. 10A)) or detrimental (+Fy—see FIG. 10B). Therefore, weight W of solar rack system 1 must take into account the upward or positive vertical force F_(y) of the external force F_(external). The protective membrane 5 is held in place normal to the roof membrane 10 by the weight of solar rack system 1 and/or anchors (such as short spikes 77 and long spikes 79 shown in FIGS. 7A and 7B).

Now turning to FIG. 2 illustrating a perspective view of the protective membrane 5 partially attached to the existing membrane 10 at various (discontinuous) attachment points 15. Attachment points 15 can be used around the entire perimeter 3 of the protective membrane 5, or on one or more sides of protective membrane 5, depending on the needs of the user. Attachment methods vary with the type of membrane. A thermoplastic membrane could be heat welded to a thermoplastic membrane, a thermoset membrane may require an adhesive tape, and dissimilar materials could be attached with an adhesive tape, contact adhesive, a built-up roof (BUR) could be attached with bitumen based mastics, sealants, or any combination thereof The guide rails 30 could sit directly on the roof membrane 10 or sit on feet or risers 31.

Now turning to FIG. 3 illustrating other embodiments of protective membrane 5 can include continuous attachment 16 on one, two, three, or four sides 17 of the membrane perimeter 3. Three sides 17 are shown in FIG. 3 to be continuously attached to the existing roof membrane 10. Attachment methods vary with the type of membrane. A thermoplastic membrane could be heat welded to a thermoplastic membrane, a thermoset membrane may require an adhesive tape, contact adhesive, a built-up roof (BUR) could be attached with bitumen based mastics, sealants, or any combination thereof. Support railings 30 can be spaced apart a distance X, for example about 3 feet to about 16 feet. FIG. 4 is a side view of an embodiment of the present invention having the protective membrane 5 and a support railing 30 for a solar rack system directly on a roof substrate or system 35 (without roof membrane 10) on top of insulation substrate 35A. The support rails 30 could sit directly on the protective membrane 5 or sit on feet or risers 31. Some embodiments of the protective membrane 5 will substantially cover roof membrane 10 or roof substrate 35 when there is no roof membrane 10 as illustrated in FIG. 11.

FIG. 5 is a side view of an embodiment of the present invention 1 having protective membrane 5 and a support railing 30 shown on top of an existing roof membrane 10. The support rails 30 could sit directly on the protective membrane 5 or sit on feet or risers 31.

FIG. 6 a is a perspective view of an embodiment of the present invention 1 having the protective membrane 5 and a connector 40 on top of an existing roof membrane 10. Connector 40 can be placed directly on the roof membrane 10 when the dead load of the solar rack system 1 requires additional support to resist loads acting normal to the roof plane, for example, wind and seismic forces that act downward. As discussed above and shown in FIGS. 10A and 10B, connector 40 will remain at rest in its predetermined position until external horizontal force Fx is greater than sliding friction Fμ. If resistance to lateral forces is required, the foot 31 or a connector 40 can be attached to the roof structure to counteract the forces. Also, base 42 of connector 40 acts as a stabilizer to counter the moment M induced by the external forces, wherein a larger base 42 distributes the moment load over a greater area. Connector 40 can be solid (not shown) or include hole 43 to receive and engage a solar array rack system (not shown). Protective membrane 5 dimensions (width W1, length L1) can be sized to be slightly larger than the dimensions (width W2, length L2) of base 42. A plurality of protective membranes 5 can be used as required under connectors 40. This feature provides for replacement of a single protective membrane 5 from under a connector 40 of smaller size than the larger protective membrane 5 intended to be a single, monolithic pad under all the connectors 40 as shown in FIGS. 1-3.

FIG. 6 b illustrates a connector 40 used to retain support rail 30 (see FIG. 1) in place. Bracket 101 includes slots 103, 105 to receive an attachment device such as nuts, bolts, or other fasteners 9 (see FIG. 1) to attach bracket 101 to connector 40 and support rail 30 (see FIG. 1) into hole 43 of shaft 54, thereby coupling connector 40 and support rail 30 to secure support rail 30. Connector 40 can be attached to the roof structure with an attachment device such as short spikes 77 (see FIG. 7) through holes 40 a in base 42 or not physically attached to the roof structure and remain a place by its own weight or ballast. Slot 103, 105 allow for variable adjustment and positioning of connector 40. Bracket 101 restrains support rail 30 from lateral and upward movement due to external forces such as wind and seismic activities.

FIGS. 7A-C illustrate other embodiments 2A-C of the present invention with a connector 40 having shaft 54 penetrating hole 63 of an existing roof membrane 10 and hole 65 of protective membrane 5. FIG. 7A illustrates only first flashing 45. FIG. 7B illustrates first flashing 45 and second flashing 47. FIG. 7C illustrates first flashing 45, second flashing 47, and third flashing 47A. All flashing embodiments provide a waterproof seal at the point or along the seam of penetration of the existing roof membrane 10. Each flashing is shown was an increasing vertical height H and horizontal length L (see FIG. 7C). Shaft 54 includes an outer surface 67 with a diameter smaller than or equivalent to the diameter of hole 65 of the protective membrane 5 and smaller than or equivalent to a hole 63 in roof membrane 10 of the roof. Roof membrane 10 is disposed between protective membrane 5 and base 42 with thickness 49 of connector 40. Base 42 is disposed between roof membrane 10 and wood blocking 50 or equivalent. First flashing 45 includes an inner surface 69 with a diameter larger than the diameter of the outer surface 67 of the shaft 54 of the connector 40, wherein the flashing 45 is disposed along the outer surface 67 of the shaft 54 of the connector 40 and between the roof membrane 10 and protective membrane 5 to provide a waterproof seal between the shaft 54 and the roof membrane 10. Second flashing 47 has an inner surface 71 with a diameter larger than the diameter of the outer surface 73 of the first flashing 45, wherein the second flashing 47 is disposed along the outer surface 73 of the first flashing 45 and along the outer surface 67 of the shaft 54 of the connector 40 and on top of the protective membrane 5 to provide a waterproof seal between the first flashing 45 and the protective membrane 5. Third flashing 47A includes an inner surface 47B with a diameter larger than the diameter of the outer surface 47C of the second flashing 47, wherein third flashing 47A is disposed along the outer surface 47C of second flashing 47 to provide a waterproof seal between second flashing 47, the first flashing 45, and the protective membrane 5.

Continuing with FIGS. 7A-C, wood blocking 50 having at least the same surface area 50A or foot print as base 42 of connector 40 is integrated within roof substrate 35, which are both attached to base structure 37 and used to provide a stable attachment point for connector 40. Attachment of connector 40 to wood blocking 50 and wood blocking 50 to base structure 37 can be accomplished by any conventional means. FIGS. 7A-C illustrates one embodiment of the attachment device being short spikes 77 and long spikes 79, respectively. Alternatively, conventional ballast (not shown) can replace the penetrating anchors, short spikes 77 and long spikes 79. Connector 40 provides resistance to external forces, such as wind or seismic forces, by transmitting the external loads through connector 40 to wood blocking 50 to structure 37. These adjacent components also act as a dampening system as well as a load transfer or load path system. The material of each component, such as metal or wood, has insulating or energy absorption characteristics to dampen the resonance frequency induced by the external forces. The thickness, length and/or width of the components can be adjusted to tune the dampening system, here being the connector 40, wooden blocking 50, and structure 37. The combination of energy transfer and dampening mechanisms provide for a system that is capable of efficient operation through the varying spectrum of vibrations because the system does not need to eliminate all vibrations. There only needs to be sufficient reduction in the vibrational modes such that the relative movement of the protective membrane 5/flashings 45, 47, 47A and the underlayment (the roof membrane 10 or roof substrate 35) at the contact edges or seams does not form a gap or fluid pathway therebetween to maintain integrity of the watertight seal.

Now turning to FIG. 8 that illustrates another embodiment of the present invention 1 having recess 53 with depth 51 substantially equivalent to thickness 49 of base 42 of connector 40 plus thickness 83 of filler material 81, such that top surface 59 of filler material 81 (such as insulation, gypsum board, and foam) is substantially flush or level with top surface 61 of roof substrate 35. The fit of base 42 within recess 53 is sufficient prevent substantial relative movement of base 42 within recess 53 to resist external forces dislodging connector 40 from recess 53. Additional, attachment devices (such as bolts or spikes) can be used to secure base 42 of connector 40 to base structure 37 of the roof. Flashings 45, 47, 47A and protective membrane 5 are attached by the same method as described above for the embodiment of FIGS. 7A-C.

Now turning to FIG. 9A that illustrates one embodiment of the present invention 1 being an array of the PV assemblies 55 positioned loosely on base structure 37 (see FIGS. 7A-C and 8), typically a horizontal roof. Solar array 55 installed on the solar panel structure protective layer 5 can be placed on either roof membrane 10 or roof substrate 35. Mounting of solar rack system 1 can be accomplished (1) without the need for fasteners and (2) without the need for wind reduction or pressure equalizing devices attached thereto.

Now turning to FIG. 9B that illustrates a perspective view of the embodiments of the present invention shown in FIGS. 1, 2, & 3 without the solar array attached thereto, as illustrated in FIG. 9A. The assembled frame 96 includes cross section members 25, center upright members 97, and end upright members 99 in slidable engagement with support rails 30 to adjust for varying widths of PV assemblies 55 (see FIG. 9A). Nuts, bolts, or other fasteners 9 (see FIG. 1) can be used to secure center upright members 97 and end upright members 99, as well as cross section members 25 discussed above. A center upright member 97 and a pair of end upright or longitudinal members 99 are generally aligned in same longitudinal plane such that back edge 55 a (see FIG. 9A) of PV assemblies 55 rest on lips 97 a, 99 a of center upright members 97 and end upright members 99, respectively. Cross section member 25 is generally aligned with front edge 55 b of (see FIG. 9A) of PV assemblies 55 such that front edge 55 b rests in lips 25 a of cross section member 25. One embodiment to the heights H1 of lips 97 a, 99 a of center upright members 97 and end upright members 99 from support rails 30 is greater than the height H2 of lips 25 a of cross section member 25 from support rails 30 to create an angle of incidence Ø of PV assemblies 55 (see FIG. 9A) above the roof

FIG. 11 is a side view of an embodiment 100 of the present invention adjacent to or mating with a corner or edge roof wall 90 of building 98. Protective membrane 5 includes an integrally formed side wall 92 with height 94 such that the projected maximum height of sustainable water on the roof is less than height 92. The overall dimensions of embodiment 100 will be equivalent to the dimensions of the rooftop for a watertight seal around the entire interior perimeter 96 of the roof. Alternative embodiments do not include the side wall 92 such that perimeter 3 (see FIG. 2) of the protective membrane 5 is substantially adjacent corner or edge 102 of roof wall 90.

Additionally, the protective membrane 5 can act as a “photon reflector” to increase energy production when provided in a white or reflective color. Special reflective color coatings may be used in lieu of white or light colored materials. The protective membrane 5 may be manufactured with reflective properties to increase the solar radiation on PV panels or solar thermal. The membranes of the invention can be a single ply membrane, polyester or polypropylene mats of varying weight, polymeric foam, or any combination thereof Additionally, the membrane material may be reinforced internally or externally. Also preferably, the membrane is made of a material that is resistant to puncture. Some commercially available products are thermoplastic and thermoset membranes with highly reflective properties in the infra-red spectrum. The membranes are available in various thicknesses.

In operation, a method of installing one embodiment of a solar array rack on top of a roof comprises the steps of: providing a support rail with rounded bottom edges and a cavity to receive the solar array rack and a membrane; laying the membrane on the top of the roof in a predetermined location without fixedly attaching the membrane to the roof; placing the support rail on the membrane without fixedly attaching the support rail to the membrane, wherein the membrane is disposed between the support rail and the top of the roof; and attaching the solar array rack to the support rail, wherein the membrane is retained in place on the roof by the combined weight of the support rail, the solar array rack, and the membrane without the use of attachments devices, such as fasteners and adhesives.

In operation, another method of installing another embodiment of a solar array rack on top of a roof comprising the steps of: positioning a connector with shaft on an optional wood blocking (the connector may also be attached directly to the structure) embedded in a roof substrate and attaching to the structure; disposing a roof membrane onto a base of the connector and a portion of the roof substrate and attaching the roof membrane to the portion of the roof substrate; placing a first flashing over an outer surface of the shaft of the connector and lowering the first flashing onto the roof membrane and attaching the first flashing to the roof membrane; disposing a roofing system and solar panel support structure layer over the first flashing and a portion of the roof membrane roof membrane without fixedly attaching the roofing system and solar panel structure protection layer to the first flashing or the portion of the roof membrane; placing a second flashing over an outer surface of the shaft of the connector and lowering the second flashing onto the roof system and solar panel support structure and attaching the second flashing to the roof membrane; and attaching the solar array rack to the connector, wherein the solar array rack is retained in place on the roof by the combined weight of the connector, the solar array rack, and the roofing system and solar panel structure protection layer without the use of attachments devices. The connector provides lateral resistance to forces in this configuration. A similar procedure is followed when using only one flashing or more than two flashings.

Also discussed above is that the protective membrane 5 is laid over the existing roof membrane 10 prior to installation of the PV system, for an existing roof An existing roof in marginal condition can receive a new solar panel structure by installing the waterproof membrane over the roof prior to installation of the solar panel structure. If there is no existing roof membrane 10, the protective membrane 5 may be placed directly on the roof substrate 35. The protective membrane 5 may be installed before the PV system installation, for example during any scheduled or unscheduled maintenance that requires disassembly or relocation of the existing solar panel structure. The protective membrane 5 may be loose laid, partially attached at the edges and/or interior, or fully adhered depending on the type of solar panel structure utilized. For example as shown in FIGS. 9A and 9B, a solar panel structure 52 including PV panel 55 can be held in place by the weight to the structure 52 with PV panel 55, protective membrane 5, support rails 30, and other components of the solar rack system may not require attachment of the membrane or ballast weights since the weight will prevent movement or slippage of the system 1 relative to the roof upper surface, for example roof membrane 10 or roof substrate 35.

The use of a membrane is a desirable preventive measure in cases where the PV array is installed on a roof and prevents access to maintain or replace the underlying substrate or roof system. If the array has to be disassembled along with the racking system the electrical system has to be taken off line, resulting in a loss of generation. The inclusion of a protection system such as the membranes of the invention minimizes damage to a roof system and lowers the lifecycle costs of the renewable energy production plant.

FIGS. 12-16B illustrate other embodiments of a rack system 100A, 100B that eliminates cross members 25 and support rails 30 or otherwise without any rails interconnecting the PV modules. Rack system 100 utilizes assemblies 102A, 102B with support posts 104A, 104B, corner bases 106, corner clamps 108, and fastening bolts 110 to retain PV modules 112 forming a unitary structure. Support posts 104A, 104B are installed on the rooftop and, as required, properly terminated into or secured on to the roof system. Corner base 106 is placed on top of support post 104A, 104B. PV modules 112 are set in place and secured using corner clamp 108 and fastening bolt 110. Spacing tab 114 of corner clamp 108 set spacing between PV modules 112. Installers can mix and match support posts 104A, 104B in the pattern or use the same support post for the entire pattern.

Now turning to FIG. 12 illustrating an exploded view of an exemplary embodiment of an assembly 102A including support post 104A, corner base 106, corner clamp 108, and fastening bolt 110. Support post 104A includes a base 120C with a bottom surface 116 having a recess 118. One embodiment of the present invention may include an adhesive or equivalent being applied to bottom surface 116 filling recess 118 to fixedly connect support post 104A to the roof system. Support post 104A also includes an upper structure 120C that can include a bolt drop 120 with a slot opening 120A sized to receive threaded shaft 126 of bolt 110 and slot base 120B sized to receive bolt head 122 of bolt 110. Corner base 106 can include hole 124 sized to receive threaded shaft 126 of bolt 110. Corner clamp 108 can include threaded hole 128 sized to receive threaded shaft 126 of bolt 110.

Now turning to FIG. 13 illustrating an exploded view of another exemplary embodiment of an assembly 102B including support post 104B, corner base 106, corner clamp 108, fastening bolt 110, and attachment devices 134. Support post 104B includes a base 136 with holes 132 sized to receive attachment devices 134 to fixedly connect support base 104B to the roof system. Support post 104B can include an upper structure 130A having a threaded hole 130 sized to receive threaded shaft 126 of bolt 110. Corner base 106 can include hole 124 sized to receive threaded shaft 126 of bolt 110. Corner clamp 108 can include threaded or unthreaded hole 128 sized to receive threaded shaft 126 of bolt 110.

Now turning to FIG. 14A that illustrates various views of a perimeter clamp 140 having an attachment hole 142 in base 144 sized to receive fastening bolt 110 for connecting perimeter clamp 104 to support post 104A, 104B (FIG. 14G). Perimeter clamp 140 can include one or more bends to form base 144, intermediate side 146, and lip 148. Bend angles θ and β can be any suitable angle greater than zero degrees and less than 180 degrees, wherein one embodiment of the present invention bend angles θ and β each range from 85 degrees to 95 degrees. Lip 148 of perimeter clamp 140 retains PV module 112 between perimeter clamp 140 and corner base 106.

Now turning to FIG. 14B that illustrates various views of a corner clamp 108 having attachment hole 124 in base 150 sized to receive fastening bolt 110 for connecting corner clamp 108 to support post 104A, 104B (FIG. 14G) to retain PV module 112 between corner clamp 108 and corner base 106. Corner clamp 108 can include spacing tab 114 along edges 152 of base 150 of corner clamp 108 to set the space between PV modules 112. A corner 162 of PV module 160 will be disposed under corner clamp 108 in shaded area 151. Spacing tab 114 includes width W1 and can be bend an angle α. Bend angle a can be any suitable angle greater than 90 degrees and less than 180 degrees, wherein one embodiment of the present invention bend angle α ranges from 120 degrees to 150 degrees. One embodiment of spacing tab 114 can be about 0.25 inches determined based on the expansion coefficient of the material.

Now turning to FIG. 14C that illustrates a top view of corner base 106 having projections 154 that act as contact surfaces to place PV modules 112 on for retention purposes as discussed above. Corner base 106 can include an attachment hole 124 sized to receive fastening bolt 110 for connecting corner base 106 to support post 104A, 104B (FIG. 14G). A corner 162 of PV module 160 will be disposed on top of corner base 106 in shaded area 155.

Now turning to FIG. 14D that illustrates two embodiments of corner base 106 having different thicknesses. The 0 degree embodiment 156 of corner base 106 has a constant thickness T1. The 1 degree embodiment 158 of corner base 106 has a varying thickness from T1 to T2. The 1 degree embodiment 158 is for illustrations purposes only and not meant to limit the invention. The actual degrees of slope can be anything greater than 0 degrees.

Now turning to FIG. 14E that illustrates a front view and a side view of support post 104A as discussed above in FIG. 12.

Now turning to FIG. 14F that illustrates a front view of support post 104B as discussed above in FIG. 13.

Now turning to FIG. 14G that illustrates an exploded side view of rack system 100A, 100B with plane P that can have a zero degree slope (P1, FIG. 15B) or greater than zero degree slope (P2, FIG. 16B). Assemblies 160 of either perimeter clamp 140, corner base 106, and support posts 104A, 104B or corner clamp 108, corner base 106, and support posts 104A, 104B are shown to retain PV modules 112 in place on a roof system. The height H1 of support posts 104A, 104B are the same as shown in FIG. 14G such that the PV module 112 has a zero slope or is flat. However, the heights of support posts 104A, 104B can vary such that the PV module 112 has a greater than zero slope or is not flat.

Now turning to FIG. 15A that illustrates a top view of rack system 100A with assemblies 160 positioned in proximity of corners 162 of PV modules 112. Rack system 100A includes support posts 104 a, 104B having the same height H1 for all assemblies 160, thereby resulting in plane P1 with a zero degree slope as illustrated in FIG. 15B.

Now turning to FIG. 16A that illustrates a top view of rack system 100B with assemblies 160 positioned in proximity of corners 162 of PV modules 112. Rack system 100B includes support posts 104 a, 104B having the different heights H1, H2 for assemblies 160, thereby resulting in plane P2 with a greater than zero degree slope as illustrated in FIG. 16B.

While the disclosure has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the embodiments. Thus, it is intended that the present disclosure cover the modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents. 

What is claimed is
 1. A solar panel support structure to mount a solar array on a roof comprising: a pair of parallel oriented guide rails, wherein each guide rail includes a length and a track extending substantially the entire length of the guide rail; at least one cross member slidably connected to the tracks of the pair of parallel oriented guide rails, wherein the at least one cross member includes a recess to receive a first edge of the solar array; a pair of longitudinal members slidably connected to the tracks of the pair of parallel oriented guide rails, wherein each longitudinal member of the pair of longitudinal members includes a recess to receive a second edge of the solar array, wherein a predetermined distance between the at least one cross member and a pair of longitudinal members defines an angle of incidence Ø of the solar array relative to an upper surface of the roof.
 2. The solar panel support structure according to claim 1, further comprising a third guide rail with a length and a track extending substantially the entire length of the third guide rail, wherein the third guide rail is disposed between the pair of parallel oriented guide rails and a center member slidably connected to the track of the third guide rail.
 3. The solar panel support structure according to claim 1, further comprising a protective membrane with a perimeter, wherein the protective membrane is disposed between the pair of parallel oriented guide rails and the upper surface of the roof without the use of ballast to retain the protective membrane on the roof.
 4. The solar panel support structure according to claim 3, wherein the protective membrane is not attached to the roof.
 5. The solar panel support structure according to claim 3, wherein the protective member comprises a plurality of edges along the perimeter, wherein one or more edges of the plurality of edges of the perimeter of the protective membrane are attached to the roof.
 6. The solar panel support structure according to claim 1, further comprising a foot disposed under at least one guide rail of the pair of parallel oriented guide rails.
 7. The solar panel support structure according to claim 3, wherein the protective membrane is not attached to at least one guide rail of the pair of parallel oriented guide rails.
 8. The solar panel support structure according to claim 3, wherein the protective membrane is attached to at least one guide rail of the pair of parallel oriented guide rails.
 9. The solar panel support structure according to claim 3, further comprising a bracket and a connector, wherein the bracket coupling the connector to at least one guide rail of the pair of parallel oriented guide rails, wherein the connector counteracts external forces acting on the solar array to maintain the at least one guide rail of the pair of parallel oriented guide rails in substantially contact with the upper surface of the roof.
 10. The roofing system according to claim 1, wherein each guide rail of the pair of parallel oriented guide rails comprises rounded bottom edges that prevent cutting of the roof along the rounded bottom edges when wind causes relative motion between the roof and the pair of parallel oriented guide rails due to uplift forces.
 11. The solar panel support structure according to claim 1, further comprising a protective membrane disposed between the guide rail and the upper surface of the roof and a ballast to retain the protective membrane on the roof with the use of penetrating anchors.
 12. A solar panel support structure to mount a solar array of a plurality of PV modules on a roof comprising: a fastening bolt having a threaded shaft and a bolt head; a support post having an upper structure and a lower structure, wherein the upper structure includes an aperture sized to receive the threaded shaft of the fastening bolt; a corner base having a through hole sized to receive the threaded shaft of the fastening bolt; and a clamp having a base with an edge, a through hole sized to receive the threaded shaft of the fastening bolt, and an outwardly extending tab along the edge, wherein the outwardly extending tab includes a bend angle a relative to the base, wherein a corner of a PV module of the plurality of PV modules is disposed between the clamp and the corner base and retained in place when the fastening bolt engages the support post and the clamp without one or more rails interconnecting the plurality of PV modules.
 13. The solar panel support structure according to claim 12, wherein the aperture of the support post comprises a slot opening sized to receive the threaded shaft of the fastening bolt and a slot base sized to receive the bolt head of the fastening bolt, wherein the slot opening is less than a width of the bolt head such that the fastening bolt is retained in the support post.
 14. The solar panel support structure according to claim 12, wherein the aperture of the support post comprises a threaded through hole sized to receive the threaded shaft of the fastening bolt.
 15. The solar panel support structure according to claim 12, wherein the outwardly extending tab of the corner clamp comprises a width to form a predetermined space between two PV modules of the plurality of PV modules.
 16. The solar panel support structure according to claim 12, wherein the bend angle a ranges between about 120 degrees and about 150 degrees.
 17. The solar panel support structure according to claim 12, wherein the corner base comprises a constant thickness such that the PV module has a zero degree slope.
 18. The solar panel support structure according to claim 12, wherein the corner base comprises a varying thickness such that the PV module has a greater than zero degree slope.
 19. The solar panel support structure according to claim 12, further comprising at least two support posts, wherein heights of the at least two support posts are the same height such that the PV module has a zero degree slope.
 20. The solar panel support structure according to claim 12, further comprising at least two support posts, wherein heights of the at least two support posts are different heights such that the PV module has a greater than zero degree slope. 